Closed structure parts, method and press forming apparatus for manufacturing the same

ABSTRACT

A closed structure part includes a body having a predetermined closed section formed by pressing a blank of a metal plate; and a latch flange portion formed by bending one of two joint ends of the body so that the joint end overlaps an outer surface of the other joint end and latches the other joint end, wherein the joint end and the other joint end overlap in contact and are respectively disposed in singular and continuous planes.

RELATED APPLICATIONS

This is a divisional of U.S. Ser. No. 13/120,227, filed Mar. 22, 2011,which is a §371 of International Application No. PCT/JP2009/067124, withan international filing date of Sep. 24, 2009 (WO 2010/035884 A1,published Apr. 1, 2010), which is based on Japanese Patent ApplicationNo. 2008-245465, filed Sep. 25, 2008.

TECHNICAL FIELD

This disclosure relates to a press forming method of manufacturing aclosed structure part having a closed section by pressing a blank formedfrom a metal plate using a press forming die to form one joint end ofthe blank into a latch flange portion and engaging the latch flangeportion with the other joint end, a press forming apparatus used for thepress forming method, a closed structure part manufactured using thepress forming method, and a closed structure part with a welded flange.

BACKGROUND

For example, to manufacture a structural part having a closed section (aclosed structure part) such as a side member or a side door of a vehicle(e.g., a motor vehicle), a plurality of sub-parts of the closedstructure part are formed from a metal plate (e.g., a steel plate) usingpress forming (i.e., press sub-parts). Thereafter, one of the pressforming sub-parts is attached to another press sub-part, and the twopress sub-parts are fixedly joined to each other by, for example,hemming or welding. In this way, a closed structure part is manufacturedfrom a plurality of press sub-parts.

An example of such a closed structure part is described in JapaneseUnexamined Patent Application Publication No. 2007-176361 (a doorstructure of a vehicle). The door structure of a vehicle described in JP'361 includes an inner panel and an outer panel each having a concaveshape. The inner panel has, in an edge portion thereof, a hemming flangebent towards the outer panel. The hemming flange is bent to pinch theedge portion of the outer panel. In this way, the inner panel is joinedto the outer panel by hemming.

In addition, Japanese Unexamined Patent Application Publication No.5-228557 describes a hemming apparatus for joining an outer panel to aninner panel by hemming (press hemming) (refer to, in particular,Paragraphs [0002] and [0003] and FIGS. 5 through 10). To join an outerpanel to an inner panel, the hemming apparatus places the inner paneland the outer panel so that the inner panel and the outer panel overlapeach other, brings a pre-hemming steel into contact with the top endportion of the hemming flange of the outer panel, and urges the top endportion in the diagonally downward direction to bend the top portion.Thereafter, the hemming apparatus moves the pre-hemming steel downwardto further bend the hemming flange. The edge portion of the inner panelis pinched by the hemming flange of the outer panel. In this way, theouter panel is joined to the inner panel by hemming.

In addition, to manufacture a front side member, which is a closedstructure part used to absorb a shock occurring when the vehiclecollides with an object, the flange portions formed for a plurality ofpress parts are firmly joined with one another using welding such asspot welding, laser welding, or arc welding.

When manufacturing the above-described closed structure part having aclosed section, a plurality of press sub-parts of the closed structurepart are formed from, for example, a steel plate by pressing.Thereafter, the press sub-parts are placed to overlap one another. Theflange portions of the press sub-parts are joined by hemming or welding.Thus, a plurality of press sub-parts are assembled into the closedstructure part.

However, in general, the weight of a closed structure part having aclosed section increases as the number of press sub-parts of the closedstructure part increases. That is, if the number of the press sub-partsincreases, a connection flange portion is needed for each of the presssub-parts. In addition, such a flange portion needs to be formed oneither end of the press sub-part with an inner space therebetween.Accordingly, as the number of the press sub-parts increases, the ratioof the weight of the flange portions to the entire weight of the closedstructure part increases. As a result, the weight of the closedstructure part is increased.

In addition, such a closed structure part is manufactured through atleast a final stage press step to form a plurality of press sub-parts ofthe closed structure part and a hemming step to join the press sub-partsto one another by hemming. In recent years, to reduce the manufacturingcost of closed structure parts, it has been required to manufactureclosed structure parts more efficiently than ever.

Accordingly, it could be helpful to provide a method and an apparatuscapable of reducing the number of sub-parts of a closed structure partand the number of steps for manufacturing the closed structure part and,therefore, efficiently manufacturing the closed structure part. It couldalso be helpful to provide a lightweight closed structure part byreducing the number of sub-parts.

SUMMARY

We thus provide a method of manufacturing a closed structure part havinga closed section using a blank made from a metal plate by pressing theblank using a press forming die and fixing a pair of joint ends of theblank to each other, characterized in that the method includes apre-forming step of processing the blank into an interim part having aclosed section corresponding to the closed structure part, a closingstep of, after the pre-forming step is completed, moving the joint endsof the interim part close to each other and urging, against one of thejoint ends, a concave flange processing portion formed on one of a pairof press forming surfaces of the press forming die at the edge endadjacent to the other press forming surface, and a press joining stepof, after the closing step is completed, further moving the pressforming die in a pressing direction, bending the one of the joint endsusing a pressing force applied from the flange processing portion sothat the joint end overlaps the outer surface of the other joint end anda latch flange portion for latching the other joint end is formed and,simultaneously, pressing the blank using the pair of press formingsurfaces and press-forming outer portions of the pair of the joint endsof the blank into predetermined shapes.

In the method of manufacturing the closed structure part, after thepre-forming step is completed, the closing step is performed. In theclosing step, the two joint ends of the interim part are moved close toeach other. In addition, an operation for urging, against one of thejoint ends, a concave flange processing portion formed on one of a pairof press forming surfaces of the press forming die at the edge endadjacent to the other press forming surface is performed. Thus, the twojoint ends can be brought closer to each other against the deformationresistance (springback) of the blank serving as the material of theclosed structure part, and one of the joint ends can be moved into theconcave flange processing portion formed on the one of the other pressforming surfaces. As a result, the distance between the two joint endsof the interim part can be sufficiently decreased, and one of the jointends can be moved into the concave flange processing portion for formingthe joint end into a latch flange portion.

In addition, in the method of manufacturing the closed structure part,after the closing step is completed, the press joining step isperformed. In the press joining step, the press forming die is furthermoved in a pressing direction. In addition, one of the joint ends isbent using a pressing force applied from the flange processing portionso that the joint end overlaps the outer surface of the other joint endand a latch flange portion for latching the other joint end is formed.Simultaneously, the blank is pressed by the pair of press formingsurfaces so that outer portions of the pair of the joint ends of theblank are press-formed into predetermined shapes. As a result, thedistance between the two joint ends can be sufficiently decreased.Thereafter, one of the joint ends can be formed into a latch flangeportion. The latch flange portion can latch the other joint end. Thus,one of the joint ends (the latch flange portion) can be fixed to theother joint end. Simultaneously, the outer portions of the two jointends of the interim part can be press-formed into a predetermined shape.

Therefore, according to the method of manufacturing the closed structurepart, a closed structure part having a closed section can bemanufactured using a blank formed from a single metal plate as amaterial. In addition, an operation to fix the two joint ends of theclosed structure part to each other and an operation to press-form theouter portions of the two joint ends can be simultaneously performed.Accordingly, the number of sub-parts of the closed structure part andthe number of steps for manufacturing the closed structure part can bereduced. As a result, the closed structure part can be efficientlymanufactured.

Furthermore, the method of manufacturing the closed structure partfurther includes a welding step of, after the press joining step iscompleted, fixing the latch flange portion to the other joint end bywelding.

Still furthermore, a press forming apparatus for use in the method ofmanufacturing the closed structure part includes the press forming dieand driving means for moving the press forming die in the pressingdirection when the closing step and the press joining step areperformed. The press forming die has a pair of press forming surfaceshaving a shape corresponding to the outer portion of the pair of jointends of the closed structure part and a concave flange processingportion formed on one of the press forming surfaces at the edge endadjacent to the other press forming surface.

According to the press forming apparatus used for manufacturing theclosed structure part, a blank formed from a single metal plate ismounted in a press forming die, and the distance between the two jointends is sufficiently decreased and, thereafter, the press forming die ismoved by the driving means in a predetermined pressing direction. Thus,one of the joint ends is formed into a latch flange portion. By latchingthe latch flange portion to the other joint end, the two joint ends canbe fixed to each other. In addition, the outer portions of the two jointends of the blank (the interim part) can be press-formed into apredetermined shape. Accordingly, a closed structure part having aclosed section can be manufactured using a blank formed from a singlemetal plate as a material. In addition, an operation to fix the twojoint ends of the closed structure part to each other and an operationto press-form the outer portions of the two joint ends can besimultaneously performed. Therefore, the number of components of theclosed structure part and the number of steps for manufacturing theclosed structure part can be reduced. As a result, the closed structurepart can be efficiently manufactured.

In addition, the press forming apparatus used for manufacturing theclosed structure part is characterized in that the depth of the flangeprocessing portion with respect to the one of the press forming surfacesis greater than or equal to 0.5 times a thickness of the blank and lessthan or equal to 4.0 times the thickness of the blank.

The closed structure part manufactured using the method includes a bodyhaving a predetermined closed section and a latch flange portion formedby bending one of two joint ends of the body so that the joint endoverlaps an outer surface of the other joint end and latches the otherjoint end.

According to the closed structure part, the latch flange portion isformed by bending one of two joint ends of the body so that the jointend overlaps an outer surface of the other joint end and latches theother joint end. Since the two joint ends of the body are fixed to eachother, the body that is a main component of the closed structure part,the latch flange portion, and the other joint end can be integrallyformed from a single metal plate (a blank). In addition, the two jointends can be fixed to each other by using only the other joint end andthe latch flange portion (one of the two joint ends) that latches theother joint end. Thus, the body can have a closed section. Accordingly,the number of sub-parts of the closed structure part can be reduced ascompared with a closed structure part formed from two or moreindependent sub-parts. Furthermore, the ratio of the weight of theflange portion to the entire weight of the closed structure part can bereduced. As a result, the weight of the closed structure part can beefficiently reduced.

In addition, the closed structure part is characterized in that a widthof the latch flange portion is set to a value greater than or equal to athickness of a blank and less than or equal to 25% of the entirecircumference of the cross section of the closed structure part.

As described above, a method of manufacturing a closed structure partand a press forming apparatus used to manufacture a closed structurepart can reduce the number of sub-parts of the closed structure part andthe number of manufacturing steps. As a result, a closed structure partcan be efficiently manufactured.

In addition, the number of sub-parts of the closed structure part can bereduced and, the weight of the closed structure part can be reduced.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1(A) and 1(B) are perspective views of a closed structure partmanufactured using a method of manufacturing a closed structure part.

FIG. 2 is a front view of a first press forming apparatus which is anapparatus for manufacturing a closed structure part.

FIG. 3 is a front view of a second press forming apparatus which is anapparatus for manufacturing a closed structure part.

FIGS. 4(A)-4(D) are front views of a press joining apparatus which is anapparatus for manufacturing a closed structure part.

FIGS. 5(A)-5(D) are front views of a modification of the press joiningapparatus which is an apparatus for manufacturing a closed structurepart.

FIGS. 6(A)-6(D) are front views of an insert core, a punch, and asupporting pad, and pressure cams used in a press joining step performedby the press joining apparatus.

FIG. 7(A) is a plan view of a blank serving as a forming material of aclosed structure part; FIG. 7(B) is a front view illustrating the shapeof the blank before the press joining step is performed; and FIG. 7(C)is a front view illustrating the shape of the blank after the pressjoining step has been performed.

FIGS. 8(A) and 8(B) are front views of a closed structure part and apunch according to Comparative Example 1.

FIGS. 9(A) and 9(B) are front views of a closed structure part and apunch according to Comparative Example 2.

FIGS. 10(A) and 10(B) are front views of a closed structure part and apunch according to Comparative Example 3.

FIGS. 11(A) and 11(B) are front views of a closed structure part and apunch according to an example.

FIGS. 12(A) and 12(B) are front views of a closed structure part and apunch according to another example.

FIGS. 13(A) and 13(B) are front views of a closed structure part and apunch according to yet another example.

REFERENCE SIGNS LIST

-   10, 12 closed structure part-   18 body-   19 joint end-   20 latch flange portion-   21 joint end-   24 blank-   26 shoulder portion-   30 first press forming apparatus-   32 die-   34 punch-   36 hydraulic actuator-   38 press forming surface-   42 slope surface-   44 press forming surface-   48 slope surface-   50 cylinder-   52 plunger-   54 bottom plate portion-   56 side plate portion-   60 second press forming apparatus-   62 die-   64 punch-   66 hydraulic actuator-   67 blank insertion portion-   68 press forming surface-   70 blank supporting surface-   74 press forming surface-   76 cylinder-   78 plunger-   80 press joining apparatus-   82 insert core (press forming die)-   83 side portion-   84 punch (press forming die)-   86 supporting pad-   88 pressure cam-   89 pressure surface-   90 hydraulic actuator (driving means)-   92 cam drive mechanism-   94 blank supporting surface-   96, 97 press forming surface-   98, 99 press forming surface-   100 blank supporting surface-   106 cylinder-   108 plunger-   120, 122, 124 closed structure part-   130, 132, 134 closed structure part

DETAILED DESCRIPTION

A method of manufacturing a closed structure part, a manufacturingapparatus used in the method, and a closed structure part manufacturedusing our method are described below with reference to the accompanyingdrawings.

Structure of Closed Structure Part

FIGS. 1(A) and 1(B) illustrate closed structure parts manufactured usinga method of manufacturing a closed structure part. Closed structureparts 10 and 12 are used as part of a side member of the body of, forexample, a motor vehicle. The closed structure parts 10 and 12 aremounted so that the length direction thereof (a direction indicated byan arrow LP) is the front-rear direction of the vehicle. The material ofeach of the closed structure parts 10 and 12 is a metal plate (ahigh-tensile steel plate). Each of the closed structure parts 10 and 12has a small tubular shape having an open end at either end.

Both ends of each of the closed structure parts 10 and 12 are parallelto each other in the length direction of a body 18. One of the endsserves as a latch flange portion 20. The other end serves as a joint end21. The body 18, the latch flange portion 20, and the joint end 21 areformed from a blank 24 made of a high-tensile steel plate using a pressforming method (see FIG. 2).

In this example, the blank 24 is formed in advance so that the planarshape thereof corresponds to the closed structure part 10 or 12 using alaser cutting process. The blank 24 has a rectangular shape so that thelength direction of the planar shape thereof corresponds to the lengthdirection of the closed structure part 10. As shown in FIG. 2, both endsof the blank 24 extending in a direction perpendicular to the lengthdirection serve as joint ends 19 and 21. For each of the closedstructure parts 10 and 12, the joint ends 19 and 21 of the blank 24 arefixed to each other. Thus, the body 18 having a closed section isgenerated.

The body 18 of each of the closed structure parts 10 and 12 may have avariety of cross-sectional shapes in accordance with a requiredinstallation space and strength of the body of the vehicle. Morespecifically, for example, the body 18 of the closed structure part 10(see FIG. 1(A)) has a cross section of a substantially regular hexagonalshape. In addition, the body 18 of the closed structure part 12 has across section of a substantially rectangular shape. The length directionof the shape corresponds to the left-right direction of the vehicle.Note that the cross-sectional shape of the body 18 is not limited to theshapes shown in FIGS. 1(A) and 1(B). For example, the cross-sectionalshape may be another polygonal shape. Alternatively, part or theentirety of the cross-sectional shape of the body 18 can be a curvedshape, such as an arc or an ellipse.

When the closed structure parts 10 and 12 are manufactured, the jointend 19 is made into the latch flange portion 20 by a press formingprocess. The latch flange portion 20 overlaps the outer surface of thejoint end 21 to latch the joint end 21. As shown in FIGS. 1(A) and 1(B),the joint end 19 of the blank 24 is bent towards the joint end 21 tofunction as the latch flange portion 20. In the state shown in FIGS.1(A) and 1(B) (a finished state), the latch flange portion 20 overlapsthe outer surface of the joint end 21 and is joined to the joint end 21using spot welding, laser welding, or arc welding.

When a side member is manufactured using such a closed structure part 10or 12, a high stiffness cap member is inserted and fixed to either endof the closed structure parts 10 or 12 in the length direction. Inaddition, a reinforcement member for reinforcing the closed structurepart 10 or 12 or a bracket, a bolt, or a nut for connecting the closedstructure part 10 or 12 to the vehicle is attached to the outerperiphery or the inner periphery of the closed structure part 10 or 12as needed. In this way, a side member, which is a component of the bodyof the vehicle, is manufactured.

Apparatus for Manufacturing Closed Structure Part

FIGS. 2 to 4(A)-(D) illustrate the structures of another example of afirst press forming apparatus, a second press forming apparatus, and apress joining apparatus used for manufacturing a closed structure part.In addition, FIGS. 2 to 4(A)-(D) illustrate closed structure partsprocessed by these apparatus during manufacturing. A forming stepperformed by the first forming apparatus or the second forming apparatusis referred to as a “pre-forming step.” A first press forming apparatus30, a second press forming apparatus 60, and a press joining apparatus80 shown in FIGS. 2 to 4(A)-(D), respectively, are used formanufacturing the closed structure part 10 having a regular hexagonalcross section or a hexagonal cross section that is elongated in thevertical direction (see FIG. 1(A)).

As shown in FIG. 2, the first press forming apparatus 30 includes apress forming die having a die 32 and a punch 34. The first pressforming apparatus 30 further includes a hydraulic actuator 36 serving asdriving means for driving the punch 34. The die 32 has a concave pressforming surface 38 in the middle of the upper surface in the widthdirection. The cross-sectional shape of the press forming surface 38along the width direction is substantially trapezoidal. The pressforming surface 38 includes slope surfaces 42 at either end thereof inthe width direction. The slope surfaces 42 extend upwards to taperoutward.

The punch 34 has a press forming surface 44 in the middle of the lowersurface in the width direction. The cross-sectional shape of the pressforming surface 44 along the width direction is substantiallytrapezoidal to correspond to the cross-sectional shape of the pressforming surface 38. The punch 34 includes slope surfaces 48 at eitherend thereof in the width direction. The cross-sectional shapes of theslope surfaces 42 correspond to those of the slope surface 42 of thepress forming surface 38.

The hydraulic actuator 36 includes a cylinder 50 and a plunger 52disposed on the inner peripheral side of the cylinder 50. The cylinder50 is fixed to a support frame (not shown) of the first press formingapparatus 30. The plunger 52 is supported by the cylinder 50 in aslidable manner along the height direction (a direction indicated by anarrow HM). The lower end of the plunger 52 is joined to the upper middleportion of the punch 34. Under hydraulic control of a hydraulic controlunit (not shown), the hydraulic actuator 36 moves the punch 34 between apress position (see FIG. 2) at which the press forming surface 44 of thepunch 34 fits together with the press forming surface 38 of the die 32and a standby position above the die 32.

As shown in FIG. 3, like the first press forming apparatus 30, thesecond press forming apparatus 60 includes a press forming die includinga die 62 and a punch 64. The second press forming apparatus 60 furtherincludes a hydraulic actuator 66 serving as driving means for drivingthe punch 64. The die 62 has a concave blank insertion portion 67 havinga substantially V shape. The blank insertion portion 67 is a recessformed in the middle of the die 62 with respect to the ends of the die62. The bottom portion of the blank insertion portion 67 has two pressforming surfaces 68 formed from two slope surfaces that form a concaveshape. Two blank supporting surfaces 70 extend from the ends of theconcave press forming surfaces 68 upwards to taper outward.

The punch 64 has a cross section of a substantially rectangular shapehaving a length direction that coincides with the height direction(indicated by the arrow HM). The lower surface of the punch 64 has twopress forming surfaces 74 that correspond to the two press formingsurfaces 68 and that form a concave shape.

The hydraulic actuator 66 includes a cylinder 76 and a plunger 78disposed on the inner peripheral side of the cylinder 76. The cylinder76 is fixed to a support frame (not shown) of the second press formingapparatus 60. The plunger 78 is supported by the cylinder 76 in aslidable manner along the height direction. The lower end of the plunger78 is joined to the upper middle portion of the punch 64. Underhydraulic control of a hydraulic control unit (not shown), the hydraulicactuator 66 moves the punch 64 between a press position (see FIG. 3) atwhich the press forming surface 74 of the punch 64 fits together withthe press forming surface 68 of the die 62 and a standby position abovethe die 62.

As shown in FIG. 4(A), the press joining apparatus 80 includes an insertcore 82 having a cross section corresponding to the cross section of thebody 18 of the closed structure part 10 which is the final part (seeFIG. 1(A)). The press joining apparatus 80 further includes a punch 84disposed above the insert core 82. The insert core 82 and the punch 84serve as a press forming die. Furthermore, the press joining apparatus80 includes a supporting pad 86 disposed beneath the insert core 82 andtwo pressure cams 88 disposed at either outer end of the insert core 82in the width direction. Still furthermore, the press joining apparatus80 includes a hydraulic actuator 90 serving as driving means for drivingthe punch 84 and a cam drive mechanism 92 that operates in conjunctionwith the hydraulic actuator 90.

The supporting pad 86 has blank supporting surfaces 94 formed from slopesurfaces that form a concave shape on the upper surface side. The shapeof the blank supporting surfaces 94 corresponds to the shape of a bottomplate portion 54 of the body 18. In addition, the punch 84 has pressforming surfaces 96 and 97 at either end of the punch 84 in the widthdirection of the lower surface. Each of the press forming surfaces 96and 97 is a slope surface that is tilted with respect to the widthdirection and the height direction. The upper edge of the press formingsurface 96 is connected to the upper edge of the press forming surface97, and the press forming surfaces 96 and 97 extend downward from theconnected edges to taper outwardly. In addition, the shape formed by thepress forming surfaces 96 and 97 corresponds to the shape of a shoulderportion 26 that is an outer portion of the latch flange portion 20 andthe joint end 21 of the body 18.

In contrast, the insert core 82 has press forming surfaces 98 and 99formed from slope surfaces on the upper side. The press forming surfaces98 and 99 correspond to the press forming surfaces 96 and 97,respectively. In addition, the insert core 82 has, as a bottom surface,a convex blank supporting surface 100 that corresponds to blanksupporting surfaces 94 of the supporting pad 86. The side surface ofeach of the pressure cams 88 on an inner side in the width directionserves as a pressure surface 89 corresponding to a side portion 83 ofthe insert core 82.

As shown in FIG. 6(A), a concave flange processing portion 102 is formedin the upper end portion of the press forming surface 97 (the leftsurface in FIG. 6(A)) of the punch 84. The concave flange processingportion 102 linearly extends in the depth direction of the punch 84throughout the length of the press forming surface 97. The surface ofpart of the press forming surface 96 having a predetermined width BPfrom the upper edge steps down with respect to the lower area of theconcave flange processing portion 102 by a predetermined depth DP. Inthis way, the concave flange processing portion 102 is formed. Inaddition, the bottom surface of the flange processing portion 102 issubstantially parallel to the press forming surface 97 extending fromthe lower edge of the flange processing portion 102.

The depth DP of the flange processing portion 102 (see FIG. 8(B)) isappropriately set to a value greater than or equal to 0.5 times athickness TB of the blank 24 serving as the material of the closedstructure part 10 (see FIG. 8(A)) and less than or equal to 4.0 timesthe thickness TB. In addition, the width BP of the flange processingportion 102 (see FIG. 8(B)) is appropriately determined in accordancewith a width BF of the latch flange portion 20 formed in the blank 24(see FIG. 8(A)). More specifically, the width BP is appropriately set toa value greater than or equal to 1.0 times the width BF and less than orequal to 2.0 times the width BF. Furthermore, the width BF of the latchflange portion 20 is appropriately set to a value greater than or equalto the thickness of the blank and less than or equal to 25% of theentire circumference of the cross section of the closed structure part.

As shown in FIG. 4(A), the hydraulic actuator 90 includes a cylinder 106and a plunger 108 disposed on the inner peripheral side of the cylinder106. The cylinder 106 is fixed to a support frame (not shown) of thepress joining apparatus 80. The plunger 108 is supported by the cylinder106 in a slidable manner along the height direction. The lower end ofthe plunger 108 is joined to the upper middle portion of the punch 84.Under hydraulic control of a hydraulic control unit (not shown), thehydraulic actuator 90 moves the punch 84 between a press position (seeFIG. 6(C)) at which the press forming surfaces 96 and 97 of the punch 84fit together with the press forming surfaces 98 and 99 of the insertcore 82 and a standby position above the insert core 82 (see FIG. 6(D)).

A pair of the cam drive mechanisms 92 operates in conjunction with theoperation performed by the hydraulic actuator 90. The cam drivemechanisms 92 move the pressure cam 88 between a standby position (seeFIG. 4(A)) to which the pressure cam 88 is moved away from the sideportion of the insert core 82 along the width direction and a pressureposition at which the pressure cam 88 is urged against the side portionof the insert core 82 in the width direction. More specifically, whenthe hydraulic actuator 90 moves the punch 84 downward from the standbyposition to the press position, the cam drive mechanism 92 moves thepressure cams 88 from the standby positions to the pressure positions.

In contrast, when the hydraulic actuator 90 moves the punch 84 upwardfrom the press position to the standby position, the cam drive mechanism92 moves the pressure cams 88 from the pressure positions to the standbypositions. While the apparatus shown in FIGS. 2 to 5 has been describedas a press forming apparatus that moves the punch using a hydraulicactuator, a press forming apparatus is not limited to such an apparatus.For example, a mechanical press machine (i.e., a widely used pressmachine) including a crank press can be used by using a similar die.

Method of Manufacturing Closed Structure Part

A method of manufacturing the closed structure part 10 using theabove-described manufacturing apparatus is described next.

In a method of manufacturing a closed structure part, a first press stepusing the first press forming apparatus 30 may be performed first. Inthe first press step, the blank 24 that has been processed and cut intoa predetermined planar shape in advance is mounted between the pressforming surface 38 of the die 32 and the press forming surface 44 of thepunch 34 of the first press forming apparatus 30. Thereafter, the punch34 located at the standby position is lowered to the press positionusing the hydraulic actuator 36. In this way, as shown in FIG. 2, theblank 24 is formed into a shape corresponding to the shape formed by thepress forming surface 38 and the press forming surface 44 (pressforming). At that time, a pair of the shoulder portions 26 of the body18 (see FIG. 3) are formed at either end of the blank 24 in the widthdirection by the slope surfaces 42 and 48.

At that time, as shown in FIG. 7(B), a width BS₁ of one of the shoulderportions 26 is made larger than a width BS₂ of the other shoulderportion 26 by a value equal to the width BF of the latch flange portion20 (see FIG. 7(A)). As shown in FIG. 3, the top ends of the shoulderportions 26 serve as joint ends 19 and 21 of the finished closedstructure part 10 (the body 18). By fixing (joining) the joint ends 19and 21 to each other, the body 18 having a closed section can be formedfrom the blank 24.

In the method of manufacturing a closed structure part, a second pressstep using the second press forming apparatus 60 may be performed afterthe first press step is completed. In the second press step, the blank24 having the pair of shoulder portions 26 formed therein through thefirst press step is mounted on the blank insertion portion 67 of the die62 of the second press forming apparatus 60. Thereafter, the punch 64located at the standby position is lowered to the press position by thehydraulic actuator 66. In this way, as shown in FIG. 3, the middleportion of the blank 24 in the width direction is formed into a shapecorresponding to the shape formed by the press forming surfaces 68 and74 (press forming). At that time, the bottom plate portion 54 of thebody 18 (see FIG. 7(B)) is formed in the middle of the blank 24 in thewidth direction. In addition, a portion of the blank 24 between each ofthe shoulder portions 26 and the bottom plate portion 54 serves as aside plate portion 56. Each of the two side plate portions 56 issupported by one of the two blank supporting surfaces 70 and is bent ata predetermined tilt angle with respect to the bottom plate portion 54.

In the method of manufacturing a closed structure part, a closing stepand a press joining step are performed using the press joining apparatus80 after the second press step has been completed. In the closing step,as shown in FIG. 4(A), the bottom plate portion 54 of the blank 24 issandwiched between the blank supporting surface 94 of the supporting pad86 and the blank supporting surface 100 of the insert core 82. At thattime, the pressure surface 89 of each of the pressure cams 88 located atthe standby position is brought into contact with the blank 24 at aposition in the vicinity of the border between the shoulder portions 26and the side plate portion 56.

Subsequently, as shown in FIG. 4(B), each of the pressure cam 88 locatedat the standby position is moved towards the pressure position using thecam drive mechanism 92. Thus, each of the side plate portions 56 ismoved (bent) towards the side portion 83 of the insert core 82 and isurged against the side portion 83 by the pressure surface 89 of thepressure cam 88. At the same time, the punch 84 located at the standbyposition is lowered towards the press position by using the hydraulicactuator 90. Thereafter, when the punch 84 is further lowered, the topsurface of one of the shoulder portions 26 (the joint end 19) is broughtinto contact with the bottom surface portion of the flange processingportion 102, as shown in FIG. 6(B). In this way, the closing step iscompleted, and the subsequent press joining step is started.

When one of the joint ends 19 is brought into contact with the flangeprocessing portion 102, a contact angle θC (see FIG. 6(B)) formed by thejoint end 19 and the bottom surface portion of the flange processingportion 102 is about 60°. Thus, when the top end portion of the jointend 19 receives a pressing force from the flange processing portion 102in a pressing direction, bending stress about a ridge line 101 betweenthe press forming surface 98 and the press forming surface 99 of theinsert core 82 occurs. Accordingly, as the punch 84 is lowered towardsthe press position, the joint end 19 is more bent about the ridge line.Thus, the top end of the joint end 19 is brought closer to the joint end21.

As shown in FIG. 6(C), when the punch 84 is lowered to the pressposition, the joint end 19, as shown in FIG. 7(C), is bent to be at apredetermined flexion angle θF (=about 120°) with respect to the jointend 19 of the shoulder portions 26. Thus, the latch flange portion 20latching the joint end 21 together is formed. The latch flange portion20 overlaps the outer surface of the joint end 21 to latch the joint end21 against an elastic restoring force of the blank 24 (springback).Accordingly, the joint end 19 (the latch flange portion 20) is fixed tothe joint end 21 (temporary joint). In this way, the press joining stepis completed.

Thereafter, as shown in FIG. 6(D), the punch 84 is raised from the pressposition to the standby position. At the same time, the insert core 82is removed from the body 18. Thus, the blank 24 having a closed sectionis removed from the press joining apparatus 80.

In the method of manufacturing a closed structure part, after the pressjoining step has been completed, a welding step may be performed using awidely used welding apparatus such as a spot welding apparatus, a laserwelding apparatus, or an arc welding apparatus. During the welding step,the latch flange portion 20 and the joint end 21 are welded togetherusing spot welding, laser welding, or arc welding. Thus, the closedstructure part 10 shown in FIG. 1(A) is manufactured.

Note that the closed structure part 12 other than the closed structurepart 10 can be manufactured through the steps that are substantially thesame as those for the closed structure part 10 by simply mounting thedies 32 and 62, the punches 34, 64, and 84, the supporting pad 86, thepressure cams 88, and the insert core 82 that correspond to the shape ofthe closed structure part to be manufactured into the first pressforming apparatus 30, the second press forming apparatus 60, and thepress joining apparatus 80 and appropriately adjusting, for example, thestrokes of the hydraulic actuators 36, 66, and 90 and the cam drivemechanism 92.

In addition, as shown in FIGS. 4(A) to 4(D), the press joining apparatus80 includes the insert core 82 and the punch 84 serving as a pressforming die. The press joining apparatus 80 performs the press joiningstep using the insert core 82 and the punch 84 in addition to thesupporting pad 86 and the pair of pressure cams 88. However, if slightlylow dimension accuracy and a slightly low accuracy of the shape of theclosed structure part 10 or 12 are allowed or if the blank 24 having anexcellent plastic formability is used, the press joining step (a pressforming process and a joining process) can be performed using only thepunch 84, the supporting pad 86, and the pair of pressure cams 88without using the insert core 82 in the press joining apparatus 80 andsupporting the blank 24 by the insert core 82 from inside, as shown inFIGS. 5(A) to 5(D).

In addition, the closed structure part 10 may be manufactured as a finalpart by welding together the latch flange portion 20 and the joint end21 of the blank 24 subjected to a press joining process. However, forexample, a through-hole may be formed in each of the latch flangeportion 20 and the joint end 21. A bolt may be disposed in thethrough-holes, and a nut is screwed into the top end portion of thebolt. Alternatively, a rivet may be disposed in the through-holes, andthe top end portion of the rivet may be flattened out. Thus, the latchflange portion 20 and the joint end 21 may be joined together.

In addition, at the same time as the press joining process, a bead maybe formed at positions in the blank 24 at which wrinkles easily occurusing the punch 84 and the insert core 82.

Operation of an Example

In the method of manufacturing a closed structure part, after the firstpress step and the second press step have been completed, the closingstep may be performed. In the closing step, the joint end 19 and thejoint end 21 of the blank 24 having a cross section corresponding to thestructure part 10 are brought closer to each other using the pair ofpressure cams 88. In addition, the bottom surface portion of the flangeprocessing portion 102 formed in the other press forming surface 97 ofthe punch 84 is brought into pressure contact with one of the joint ends19. Thus, the joint ends 19 and 21 are brought closer to each otheragainst the deformation resistance (springback) of the blank 24 formedinto an interim part. Since one of the joint ends 19 can be moved intothe concave flange processing portion 102 formed in the other pressforming surface 97, the joint end 19 can be moved into the flangeprocessing portion 102 used for forming the latch flange portion 20while sufficiently reducing the distance between the joint ends 19 and21 of the blank 24.

In addition, in the method of manufacturing a closed structure part,after the closing step is completed, a press joining step is performed.In the press joining step, the punch 84 is further moved in the pressingdirection. The joint end 19 of the blank 24 is bent by a pressuringforce applied from the flange processing portion 102. Thus, the jointend 19 overlaps the outer surface of the joint end 21 and is formed intothe latch flange portion 20 for latching the joint end 21. At the sametime, the blank 24 is pressurized by the press forming surfaces 96 and97, and the shoulder portions 26 of the blank 24 are press-formed intopredetermined shapes.

In this way, the distance between the joint ends 19 and 21 issufficiently reduced. Thereafter, the joint end 19 is made into thelatch flange portion 20. By using the latch flange portion 20, the jointend 21 is latched. Thus, the joint end 19 (the latch flange portion 20)can be fixed to the joint end 21. At the same time, the two shoulderportions 26 of the blank 24 can be press-formed into predeterminedshapes.

Therefore, in the method of manufacturing a closed structure part, theclosed structure part 10 having a closed section can be manufacturedfrom the blank 24 made from a single high-tensile steel plate. Inaddition, the operation for fixing the joint ends 19 and 21 of theclosed structure part 10 to each other and the operation forpress-forming the two shoulder portions 26 can be simultaneouslyperformed. Accordingly, the number of sub-parts and the number ofmanufacturing steps of the closed structure part 10 can be reduced. As aresult, the closed structure part 10 can be efficiently manufactured.

In addition, according to the press joining apparatus 80, the blank 24made from a single metal plate is mounted on the insert core 82 and thepunch 84 that serve as a press forming die and the supporting pad 86.Thereafter, the punch 84 is moved in a predetermined pressing directionby using the hydraulic actuator 90. Thus, the distance between the jointends 19 and 21 is sufficiently reduced. Subsequently, the joint end 19is press-formed into the latch flange portion 20. By using the latchflange portion 20, the joint end 21 can be latched. In this way, thejoint end 19 and the joint end 21 can be fixed to each other. Inaddition, the two shoulder portions 26 of the blank 24 can bepress-formed into predetermined shapes. Accordingly, the closedstructure part 10 having a closed section can be manufactured from theblank 24. In addition, the operation for fixing the joint ends 19 and 21of the closed structure part 10 to each other and the operation forpress-forming the two shoulder portions 26 can be simultaneouslyperformed. Accordingly, the number of sub-parts and the number ofmanufacturing steps of the closed structure part 10 can be reduced. As aresult, the closed structure part 10 can be efficiently manufactured.

Furthermore, in the closed structure part 10 or 12, the latch flangeportion 20 may be formed by bending one of the joint ends 19 of the body18. The latch flange portion 20 overlaps the outer surface of the otherjoint end 21 and latches the other joint end 21. Thus, the joint ends 19and 21 of the body 18 are fixed to each other. In this way, the body 18,the latch flange portion 20, and the joint end 21 serving as maincomponents of the closed structure part 10 or 12 can be integrallyformed from the blank 24 made from a single metal plate. In addition,the joint ends 19 and 21 can be fixed to each other by using only thejoint end 21 and the latch flange portion 20 (the joint end 19) thatlatches the joint end 21. Thus, the body 18 can have a closed section.Accordingly, the number of sub-parts of the closed structure part 10 or12 can be reduced as compared with a closed structure part formed fromtwo or more independent sub-parts. In addition, the ratio of the weightof the flange portion to the entire weight of the closed structure part10 or 12 can be reduced. As a result, the weight of the closed structurepart 10 or 12 can be efficiently reduced.

Example of Press Joining Apparatus

The dimensions of the main sub-parts of the punch 84 of the pressjoining apparatus 80 and the reason for selecting the dimensions aredescribed next as an example.

As described above, the depth DP of the flange processing portion 102 isappropriately set to a value greater than or equal to 0.5 times thethickness of the blank 24, which is the material of the closed structurepart 10, and less than or equal to 4.0 times the thickness. This isbecause if the depth DP is set to a value less than 0.5 times thethickness of the blank 24, the pressuring force applied from the flangeprocessing portion 102 and transferred to the other joint end 21 via thelatch flange portion 20 becomes too large and, therefore, the shoulderportion 26 having the joint end 21 formed therein may deform (a shapedefect may occur). In contrast, if the depth DP is set to a valuegreater than 4.0 times the thickness of the blank 24, the flexion angleθF of the latch flange portion 20 (see FIG. 7(C)) is smaller than thedesign value. Thus, it is difficult for the latch flange portion 20 toreliably latch the other joint end 21.

Example of Latch Flange Portion

The dimensions of the latch flange portion 20 of the closed structurepart 10 or 12 and the reason for selecting the dimensions are describednext as an example.

As described above, the width BF of the latch flange portion 20 isappropriately set to a value greater than or equal to the thickness ofthe blank and less than or equal to 25% of the entire circumference ofthe cross section of the closed structure part. This is because if thewidth BF is less than the thickness of the blank, it is difficult forthe latch flange portion 20 to reliably latch the other joint end 21. Inaddition, it is difficult to continuously weld the latch flange portion20 and the joint end 21 in the length direction. In contrast, if thewidth BF is greater than 25% of the entire circumference of the crosssection of the closed structure part, the ratio of the weight of thelatch flange portion 20 to the entire weight of the closed structureparts 10 or 12 becomes too large. Thus, the weight of the closedstructure parts 10 or 12 is disadvantageously increased.

In addition, the width BP of the flange processing portion 102 isappropriately set to a value greater than or equal to 1.0 times thewidth BF of the latch flange portion 20 and less than or equal to 2.0times the width BF. This is because if the width BP is less than 1.0times the width BF, the buckling distortion of the latch flange portion20 in a direction perpendicular to the length direction easily occursand, therefore, the flatness of the latch flange portion 20 maydecrease. In contrast, if the width BP is greater than 2.0 times thewidth BF, the width of the other press forming surface 97 is too smallwith respect to the width of the shoulder portion 26 having the jointend 21 formed therein. Thus, it is difficult to sufficiently performpress forming of the shoulder portion 26.

Examples and Comparative Examples of Closed Structure Part

Closed structure parts manufactured using the method for manufacturing aclosed structure part are described below as Examples 1 to 3. Inaddition, closed structure parts manufactured using a method formanufacturing a closed structure part that does not meet our conditionsare described below as Comparative Examples 1 to 3.

In Comparative Example 1, a cold-rolled steel having a thickness TB of1.2 mm and a tensile strength of 1180 MPa is employed as the blank 24.Such a blank 24 is subjected to a press joining process using the pressjoining apparatus 80. Thus, as shown in FIG. 8(A), a closed structurepart 120 serving as an interim part is formed (press-formed). The closedstructure part 120 has a hexagonal cross section that is slightlyelongated in the vertical direction as compared with a substantiallyregular hexagonal cross section and a regular hexagonal cross section.The entire length of the closed structure part 120 is 400 mm. Inaddition, the width BF of the latch flange portion 20 is set to 10 mm.

However, the punch 84 (see FIG. 8(B)) having a depth DP of the flangeprocessing portion 102 of 0.5 mm (0.4 times the thickness TB) and awidth BP of 8 mm (0.8 times the width BF) is employed for the pressjoining apparatus 80.

In contrast, in Comparative Example 2, a cold-rolled steel having athickness TB of 1.2 mm and a tensile strength of 1180 MPa is employed asthe blank 24. Such a blank 24 is subjected to a press joining processusing the press joining apparatus 80. Thus, as shown in FIG. 9(A), aclosed structure part 122 serving as an interim part is formed(press-formed). The closed structure part 122 has a cross section thatis the same as that of the closed structure part 120. The entire lengthof the closed structure part 122 is 400 mm. In addition, the width BF ofthe latch flange portion 20 is set to 10 mm.

However, the punch 84 (see FIG. 9(B)) having a depth DP of the flangeprocessing portion 102 of 6 mm (5 times the thickness TB) and a width BPof 30 mm (3 times the width BF) is employed for the press joiningapparatus 80.

In contrast, in Comparative Example 3, a cold-rolled steel having athickness TB of 1.2 mm and a tensile strength of 1180 MPa is employed asthe blank 24. Such a blank 24 is subjected to a press joining processusing the press joining apparatus 80. Thus, as shown in FIG. 10(A), aclosed structure part 124 serving as an interim part is formed(press-formed). The closed structure part 124 has a cross section thatis the same as that of the closed structure part 120. The entire lengthof the closed structure part 124 is 400 mm. However, the width BF of thelatch flange portion 20 is set to 1 mm.

In addition, the punch 84 (see FIG. 10(B)) having a depth DP of theflange processing portion 102 of 1.2 mm (1 times the thickness TB) and awidth BP of 4 mm (double the width BF) is employed for the press joiningapparatus 80.

In contrast, in Example 1, a cold-rolled steel having a thickness TB of1.2 mm and a tensile strength of 1180 MPa is employed as the blank 24.Such a blank 24 is subjected to a press joining process using the pressjoining apparatus 80. Thus, as shown in FIG. 11(A), a closed structurepart 130 serving as an interim part is formed (press-formed). The closedstructure part 130 has a cross section that is the same as that of theclosed structure part 120. The entire length of the closed structurepart 130 is 400 mm. In addition, the width BF of the latch flangeportion 20 is set to 10 mm.

In addition, the punch 84 (see FIG. 11(B)) having a depth DP of theflange processing portion 102 of 1.2 mm (1 times the thickness TB) and awidth BP of 15 mm (1.5 times the width BF) is employed for the pressjoining apparatus 80.

In contrast, in Example 2, a cold-rolled steel having a thickness TB of1.2 mm and a tensile strength of 1180 MPa is employed as the blank 24.Such a blank 24 is subjected to a press joining process using the pressjoining apparatus 80. Thus, as shown in FIG. 12(A), a closed structurepart 132 serving as an interim part is formed (press-formed). The closedstructure part 132 has a cross section that is the same as that of theclosed structure part 130. The entire length of the closed structurepart 132 is 400 mm. In addition, the width BF of the latch flangeportion 20 is set to 30 mm.

In addition, the punch 84 (see FIG. 12(B)) having a depth DP of theflange processing portion 102 of 1.2 mm (1 times the thickness TB) and awidth BP of 30 mm (1 times the width BF) is employed for the pressjoining apparatus 80.

In contrast, in Example 3, a cold-rolled steel having a thickness TB of1.2 mm and a tensile strength of 1180 MPa is employed as the blank 24.Such a blank 24 is subjected to a press joining process using the pressjoining apparatus 80. Thus, as shown in FIG. 13(A), a closed structurepart 134 serving as an interim part is formed (press-formed). The closedstructure part 134 has a substantially square cross section. The entirelength of the closed structure part 134 is 400 mm. In addition, thewidth BF of the latch flange portion 20 is set to 10 mm.

In addition, as shown in FIG. 13(B), the punch 84 having the entirety ofthe other press forming surface 97 serving as the flange processingportion 102 is employed for the press joining apparatus 80. The width BPof the flange processing portion 102 is set to 15 mm (1.5 times thewidth BF), and the depth DP is set to 1.2 mm (1 times the thickness TB).In this example, the width BP of the flange processing portion 102 isequal to the distance between a reference position of the press formingsurface 97 determined when the latch flange portion 20 is not present(the position indicated by the two-dot chain line shown in FIG. 13(B))and the bottom surface portion of the flange processing portion 102.

A method of evaluating the closed structure parts 120, 122, and 124according to the Comparative Examples and the closed structure parts130, 132, and 134 according to our Examples is described next. A gapdistance GB (a maximum value) between the joint ends 19 and 21immediately before the blank 24 was subjected to a press joining processusing the press joining apparatus 80 and a gap distance GA (a maximumvalue) between the joint ends 19 and 21 immediately after the blank 24was subjected to a press joining process were measured. In such a case,to increase the welding performance, it is desirable that the gapdistance GA be minimized. If the gap distance GA is about 0.3 mm, thelatch flange portion 20 and the joint end 21 can be reliably weldedtogether without externally holding the latch flange portion 20 and theother joint end 21. In addition, after the press forming was performed,the cross-sectional shape of the body 18 and the shape of the latchflange portion 20 were inspected, and the inspection result of theshapes was used as an evaluation item. In TABLE 1, “◯” indicates thatthe cross-sectional shape of the body 18 and the shape of the latchflange portion 20 are normal. “x” indicates that at least one of thecross-sectional shape of the body 18 and the shape of the latch flangeportion 20 does not meet the design shape.

Evaluation for the closed structure parts 120, 122, and 124 and theclosed structure parts 130, 132, and 134 is shown in TABLE 1.

TABLE 1 Comparative Closed Gap Gap Evaluation of Cross- Example NumberStructure Distance Distance Sectional Shape and and Example Number PartNumber GB (mm) GA (mm) Shape of Latch Flange Portion Comparative Example1 120 10 0.2 X bad (Latch Flange Portion Deformed) Comparative Example 2122 10 3.0 X bad Comparative Example 3 124 10 8.0 X bad (Closed SectionNot Generated) Example 1 130 10 0.2 ◯ good Example 2 132 10 0.2 ◯ goodExample 3 134 10 0.2 ◯ good

1. A closed structure part comprising: a body having a predetermined closed section formed by pressing a blank of a metal plate; and a latch flange portion formed by bending one of two joint ends of the body so that the joint end overlaps an outer surface of the other joint end and latches the other joint end, wherein the joint end and the other joint end overlap in contact and are respectively disposed in singular and continuous planes.
 2. The closed structure part according to claim 1, wherein the latch flange portion latches the joint end against an elastic restoring force of the blank.
 3. The closed structure part according to claim 1, wherein a width of the latch flange portion is set to a value greater than or equal to a thickness of a blank and less than or equal to 25% of the entire circumference of the cross section of the closed structure part. 